Battery terminal connector and housing assembly

ABSTRACT

A battery terminal post receives a split connector cap formed of compatible metal. The cap is attached by a clip device to an exposed end of a battery cable and the clip embraces a shank portion of the connector cap adjacent to a shoulder which prevents movement of the clip axially. A screw-threaded clamping or pressure sleeve has a knurled end for coacting engagement with a knurled face on the connector cap whereby loosening of the pressure sleeve due to reverse torquing will be avoided. The pressure sleeve is received in a threaded bore of a housing element which covers and protects the connector cap and battery terminal post.

United States Patent 11 1 IIIIA Wening Feb. 18, 1975 BATTERY TERMINAL CONNECTOR ANI) 3,790,920 2/1974 Wening 339/237 x HOUSING ASSEMBLY FOREIGN PATENTS OR APPLICATIONS Inventor: Richard Wening, 2113 North 57,912 5/1953 France 151/415 Eastside St., Santa Ana, Calif. 92701 Primary Examiner-R0y Lake 22 Filed; ()CL 11, 1973 Assistant Examiner-E. F. Desmond [21] App! No: 405,587 Attorney, Agent, or Firm-B. P. Fishburne, Jr.

Related U.S. Application Data [57] ABSTRACT [63] coml'wationiinpan of 2931334 sept' A battery terminal post receives a split connector cap 1972 formed of compatible metal. The cap is attached by a clip device to an exposed end of a battery cable and 2% F' 'i 3 16 339/230 R the clip embraces a shank portion of the connector l r9l3/54 cap adjacent to a shoulder which prevents movement 1 7 R 4 of the clip axially. A screw-threaded clamping or pres- 89 i 9 9 3 sure sleeve has a knurled end for coacting engagement 5 5 5 5 with a knurled face on the connector cap whereby loosening of the pressure sleeve due to reverse torqu- [56] References C'ted ing will be avoided. The pressure sleeve is received in UNITED STATES PATENTS Y a threaded bore of a housing element which covers 827,562 7/1906 Pollock et al l5l/4l.5 and protects the connector cap and battery terminal 2057,602 lO/l936 Wilson 339/272 R X post, 1 2,925,579 2/1900 Osborn 339/116 R X 3,718,891 2/1973 Wening 339/116 R 1 Chum, 10 Drawing Flgures PATENTEUFEBVI 81975 SHEET 2 BF 3 l BATTERY TERMINAL CONNECTOR AND HOUSING ASSEMBLY This application is a continuation-in-part of my prior copending application Ser. No. 293,334, filed Sept. 29, 1972, for BATTERY TERMINAL CONNECTOR AND HOUSING, now US. Pat. No. 3,790,920, issued Feb. 5, 1974.

The principal objective of this invention is to further improve upon the efficiency of the connector and housing means shown in the above-referenced copending application and in my prior US. Pat. No. 3,718,891, issued Feb. 27, 1973. In both of these prior art structures, some problems have been encountered at the point of attachment of the battery cable to the connec tor cap. The present invention completely solves this problem through the provision of a unique connector clip which surrounds a shouldered shank of the connector cap and has positive engagement with the exposed end of the battery cable through the medium of teeth on the clip which prevent slippage of the cable. Electrical conductivity and current flow from the battery is also strengthened by the improvement. A flange or shoulder on the shank of the connector cap prevents axial movement of the clip relative to the connector cap. The improvement also reduces significantly the number of sizes or models required to accommodate a range of battery cables, and a single connector cap and clip may receive a number of different cable sizes. In a modification of this feature, similar advantages are obtained by the use of a clamping plate for the battery cable which receives threaded fasteners.

A second significant improvement resides in the use of knurled coacting faces on the leading end of the threaded pressure sleeve and rear face of the connector cap. The resulting interference when the pressure sleeve is tightened is sufficient to resist reaction forces tending to loosen the pressure sleeve.

Other features and advantages of the invention will become apparent during the course ofthe following description.

BRIEF DESCRIPTION OF DRAWING FIGURES FIG. 1 is a central vertical section through a battery terminal connector and housing assembly embodying the invention.

FIG. 2 is an exploded perspective view of components employed in the assembly.

FIG. 3 is a horizontal section taken on line 3-3 of FIG. 1.

FIG. 4 is a transverse vertical section taken on line 4-4 of FIG. 3.

FIG. 5 is an end elevation of a screw-threaded pres sure sleeve.

FIG. 6 is an exploded perspective view ofa modified form of connector cap and cable attaching means.

FIG. 7 is an enlarged transverse section taken on line 7-7 of FIG. 6.

FIG. 8 is a vertical section showing a modification of cable attaching means.

FIG. 9 is a similar view of another modification of the invention.

FIG. 10 is a similar view of still another modification.

DETAILED DESCRIPTION Referring to the drawings in detail wherein like numerals designate like parts, the numeral 10 designates a split connector cap formed of antimony and lead or the like and having a somewhat tapered bore 11 to re ceive a terminal post 12 of a storage battery 13, such as a lead-acid storage battery of the type used in auto-- The split connector cap 10 is divided at the center of its leading end 14 as shown at 17 and at its rear end the connector cap has an integral reduced shank 18 which is also semi-circular in cross section and undercut on its outer surface to form a shoulder or flange 19 in spaced opposed relation to the rear face 20 of the connector cap body portion. The rear face 20 which is normal to the axis of the shank 18 is knurled radially, preferably with a medium straight knurl, although in some instances a diamond knurl or the like may be employed. The top surface of the shank 18 has a semi-cylindrical recess 21 formed therein, having a short undercut section 22 of increased diameter at the rear end of the shank.

The recess 21 is adapted to receive the exposed wire end portion 23 of a battery cable 24 whose insulation 25 enters the undercut recess portion 22 in assembly. A connector clip 26 formed of beryllium copper constitutes an important feature of the invention now to be described. The clip 26 has an arcuate lower extension 27 which surrounds and embraces the semi-cylindrical shank 18 of the connector cap 10 below the flat upper face 16 thereof. The extension 27 terminates in a short rolled lip 28 to facilitate easy application of the clip to the shank 18. The top wall 29 of the clip 26 is flat and terminates in a short upturned lip 30, also for ease of application of the clip to a cable. A plurality of downwardly struck sharp teeth 31 are formed in the top wall 29 for penetration into the exposed wire end portion 23 of the battery cable 24 when the clip is applied to the battery cable and connector cap and firmly clenched around these elements. The shoulder or flange 19 of the connector cap 10 will prevent axial movement of the clip 26 in the assembly, FIG. 1, and the teeth 31 penetrating into the wire portion 23 of the battery cable 24 will prevent slippage of the cable relative to the clip and connector cap 10.

As best shown in FIG. 4, the recess 21 and the clip 26 are sized to accommodate a considerable range of battery cable sizes, both above and below the size depicted in the drawings, thus reducing to a minimum the number of connector cap sizes required and rendering the assembly economical from manufacturing and marketing standpoints. The cable 24, connector cap 10 and clip 26 thus constitute a sub-assembly which is easy to put together and very secure.

The assembly further comprises a preferably clear plastic housing 32 formed from a thermoplastic resin, such as Valox 420. manufactured and sold by General Electric Company, Section 122, Plastics Department, One Plastics Ave., Pittsfield, Mass. 0120]. The housing 32 has a forward chamber 33 receiving and enclosing the body portion of the connector cap 10 and battery post 12, FIG. 1. This chamber 33 has a flat top wall 34 engaging the flat upper face of connector cap 10 and a semi-circular frontal wall 35 which engages the rounded end 14 of the split connector cap 10 with a camming action, to be further described.

The lower wall 36 of housing 32, parallel to the top wall 34, has a circular opening 37 receiving the battery post 12, and an annular groove 38 in the opening 37 receives a compressible O-ring 39 which forms a tight seal around the post 12 and excludes moisture and corrosive fumes from the interior of the housing 32. The housing further comprises a rear axial extension 40 which is essentially cylindrical, enlarged and internally screw-threaded at 41. The extension 40 is joined to the forward section of the housing 32 by a vertical wall portion 42, as shown. Substantially, the housing 32 is identical to the housing disclosed in the aforementioned copending application Ser. No. 293,334.

The final component of the connector and housing assembly comprises a clamping or pressure sleeve 43 which is generally cylindrical and externally screwthreaded at 44 and provided at its rear end with a polygonal head 45 to facilitate tightening and loosening. The pressure sleeve 43 is also preferably formed of Valox 420 plastics material, as previously described. The pressure sleeve has screw-threaded engagement within the housing extension 40 and has a generous interior bore 46 to receive and clear the clip 26 and associated parts. The outer end wall of pressure sleeve 43 has a central beveled opening 47 snugly receiving the leading insulated portion of cable 24 which projects inside of the bore 46.

The leading end face 48 of pressure sleeve 43 is provided with a radially arranged medium straight knurl, or other suitable knurl, and when the pressure sleeve 43 is fully tightened, this knurled end face 48 engages the rear knurled end face 20 of connector cap and establishes an interference which prevents loosening of the pressure sleeve by vibration or by reverse torque caused by the reaction of the connector cap against the rotary pressure sleeve. Suffice it to say that the interengagement of the knurling on the two parts will overcome the reaction forces and prevent accidental loosening of the sleeve, thus rendering the assembly very secure. This knurled interengaging feature constitutes a major improvement.

In applying the connector and housing assembly to the battery terminal post 12, the sub assembly consisting of connector cap 10, cable 24 and connector clip 26 is first completed and introduced into the rear of housing 32. The pressure sleeve 43 at this time may be mounted over cable 24 but in a retracted out-of-theway position. The entire assembly is then placed downwardly over the post 12 until the O-ring 399 is tightly compressed and forms a good seal. The pressure sleeve 43 is then moved forwardly and threaded into the extension 40 and tightened firmly with a wrench. This tightening will cause the camming action between the curved end wall 35 and the curved forward face of the cap 10 to effectively close the split connector cap around the post 12 until the connector cap tightly grips the battery post. When this condition is achieved, the required interference engagement of the knurled faces and 48 will have been established and the assembly is securely locked and will not become loosened by vihration or reaction forces. It will require reverse wrenching of the pressure sleeve 43 to loosen and separate the assembly from the battery post.

In FIGS. 6 and 7, there is shown a modification of the connector cap and cable fastening means wherein the clip 26 is eliminated- In these figures, the connector cap 10 has a shank 49 provided with a semi-cylindrical recess 50 to receive the cable end 23. In lieu of the clip 26, a ridged clamp plate 51 is applied over the cable end 23 in clamping relation thereto and is coupled to the upper flat face 16 of the shank 49 by screws 52 and nuts 53. If desired, the nuts may be omitted and the screws 52 may directly engage threaded openings 54 in the shank 49. When the nuts are used. the openings 54', FIG. 7, are unthreaded. All other parts of the assembly and their functions conform exactly to what has already been described in connection with FIGS. 1 through 5.

FIG. 8 shows a further modification of the invention wherein the exposed cable end 23 of battery cable 24 is attached to a connector cap 55 by the use of a side or radial set screw 56 received by a threaded opening 57 in the top of the after portion of the connector cap 55. The connector cap 55 also has a rear end opening 58 formed at right angles to and intersecting the threaded opening 57 and this rear end opening receives the cable end 23. The arrangement is very secure and allows the assembly to receive different sizes of cables without difficulty. The insertion of the cable end in the opening 58 is a simple matter and the subsequent tightening of set screw 56 forms a very secure connection and also assures firm electrical contact. The presence of the set screw in no way interferes with the operation of the threaded pressure sleeve 43, above-described, for the housing 32. These elements of the assembly may remain identical in construction and function to the previous embodiments already described. Except for the addition of means to accommodate the set screw 56 and cable end 23 in FIG. 8, the remainder of the connector cap 55 and its funtion in the invention remains unchanged from the already-described embodiments.

FIG. 9 shows another modification of the invention constructed to accommodate the cable assemblies of automobiles which have been equipped with side terminal batteries, the owners of such automobiles desiring at a later date to buy and use standard type batteries. In the well-known side terminal batteries, the terminals are recessed into one side of the battery casing rather than being positioned on top of the battery in the form of upstanding posts. One maker of such a battery is the Delco Division of General Motors Corp., Detroit, Michigan. Such battery is designated on the market as Delco Energizer/ST.

Referring to FIG. 9, the previously-described housing 32 and pressure sleeve 43 are shown and remain unchanged. The connector cap 59, however, is modified to provide an integral rear cylindrical sleeve extension 60 having a central axial threaded bore 61 to receive therein the threaded connector screw 62 of the side terminal battery cable assembly 63. In short, the provision of the threaded opening 61 in the connector cap 59 adapts the invention to the cable assembly of side terminal batteries and no other alteration of the invention structure is, required for this adaptation.

FIG. 10 shows another modification of the invention allowing the same to be employed for marine installations to attach auxiliary wires for lights, poweroperated reels and other assessories in addition to the main starting cable. In FIG. 10, again the housing 32 and pressure sleeve 43 remain unchanged. The connector cap 64 is modified to provide thereon a rear end reduced diameter screw-threaded extension 65 and an annular shoulder 66 immediately ahead of this extension and somewhat rearwardly of pressure sleeve 43.

This particularly construction is intended to be used with marine batteries. A flat electrical terminal 67 from a wire or cable 68 is assembled over the extension 65 and securely clamped mechanically and electrically by a wing nut 69 or the like. It might be mentioned that the embodiment of FIG. 9 constructed for side terminal battery cables can easily be converted to the usage shown in FIG. 10 by the application in the threaded opening 61 of a male threaded stud sufficiently long to project rearwardly of the sleeve 43 to the extent shown in FIG. 10.

Thus it may be seen that the invention is quite versatile and is quite easily adaptable to a variety of types of installations. All disclosed embodiments of the invention, however, possess the salient features described in FIGS. 1 through 6 pertaining to the curved and split connector cap 10 and 10' having the knurled face 20 to coact with the knurled face 48 of pressure sleeve 43, and the cooperating housing 32 having the rounded front wall 35, etc.

It is to be understood that the forms of the invention herewith shown and described are to be taken as preferred examples of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from the spirit of the invention or scope of the subjoined claims.

I claim:

1. A battery terminal connector and housing assembly comprising a split connector cap having a bore to receive a battery terminal post, said connector cap having a rear shank and said shank having an axial opening in its rear end adapted to receive a battery cable end, said shank having a radial threaded opening intersecting said axial opening. a clamping set screw engaged in said threaded opening and adapted to clampingly engage said battery cable end, said connector cap having a rear serrated end face at the forward end of said shank and extending around the lower end of said shank substantially in a semi-circular arc. a housing member for said connector cap and battery terminal post and shaped with relation to said cap to cause the cap to grip the post in response to forward pressure on said serrated end face, said housing member having a rear enlarged internally threaded sleeve portion surrounding said shank, and a pressure sleeve having external screw-threads engaged within the screw-threads of said sleeve portion and forming therewith an enclosure for said shank, battery cable end and set screw, said pressure sleeve having a rear end opening adapted to receive and snugly engage the insulated portion of a battery cable, said pressure sleeve having an annular forward serrated end face adapted to engage the semicircular serrated end face of the cap when the pressure sleeve is tightened, the serrations of said faces resisting loosening of the pressure sleeve. 

1. A battery terminal connector and housing assembly comprising a split connector cap having a bore to receive a battery terminal post, said connector cap having a rear shank and said shank having an axial opening in its rear end adapted to receive a battery cable end, said shank having a radial threaded opening intersecting said axial opening, a clamping set screw engaged in said threaded opening and adapted to clampingly engage said battery cable end, said connector cap having a rear serrated end face at the forward end of said shank and extending around the lower end of said shank substantially in a semi-circular arc, a housing member for said connector cap and battery terminal post and shaped with relation to said cap to cause the cap to grip the post in response to forward pressure on said serrated end face, said housing member having a rear enlarged internally threaded sleeve portion surrounding said shank, and a pressure sleeve having external screw-threads engaged within the screw-threads of said sleeve portion and forming therewith an enclosure for said shank, battery cable end and set screw, said pressure sleeve having a rear end opening adapted to receive and snugly engage the insulated portion of a battery cable, said pressure sleeve having an annular forward serrated end face adapted to engage the semi-circular serrated end face of the cap when the pressure sleeve is tightened, the serrations of said faces resisting loosening of the pressure sleeve. 